Drive for System for Processing Fiber Optic Connectors

ABSTRACT

An apparatus for moving a fiber including a plurality of fiber optic connectors through a system for processing the plurality of fiber optic connectors. The apparatus can include a first drive mechanism for moving the fiber through the system, such as a cart and a conveyor. The apparatus can include a second drive mechanism for moving the plurality of fiber optic connectors through the system, such as a screw drive. The apparatus can also include a controller for coordinating movement of the first drive mechanism with the second drive mechanism.

TECHNICAL FIELD

The present disclosure relates generally to systems and methods forprocessing fiber optic connectors.

BACKGROUND

Fiber optic cables are used in the telecommunication industry totransmit light signals in high-speed data and communication systems. Astandard fiber optic cable includes a fiber with an innerlight-transmitting optical core. Surrounding the fiber typically is areinforcing layer and an outer protective casing. A fiber terminates ata fiber optic connector. Connectors are frequently used tonon-permanently connect and disconnect optical elements in a fiber optictransmission system. Connectors are typically coupled together throughthe use of an adaptor. An example adapter is shown in U.S. Pat. No.5,317,663, the disclosure of which is incorporated by reference.

There are many different fiber optic connector types. Some of the morecommon connectors are FC and SC connectors. Other types of connectorsinclude ST and D4-type connectors.

FIG. 1 shows an example SC connector 10 that includes a ferrule 12. Theferrule 12 is a relatively long, thin cylinder preferably made of amaterial such as ceramic. Other materials such as metal or plastic canalso be used to make the ferrule 12. The ferrule 12 defines a centralopening 14 sized to receive a fiber of a given cladding diameter. Anepoxy is typically placed into the opening 14 prior to inserting thefiber to hold the fiber in place. The ferrule 12 functions to align andcenter the fiber, as well as to protect it from damage.

Referring still to FIG. 1, the ferrule 12 is positioned within a ferrulehousing 18 typically made of a material such as metal or plastic. Anouter grip 19 is mounted over the ferrule housing 18. The housing 18 isexternally keyed to receive the grip 19 at a single rotationalorientation. A hub assembly 20 spring biases the ferrule 12 toward thefront of the connector 10. A crimp sleeve 37 and boot 28 are located atthe rear of the connector 10.

As described at U.S. Pat. No. 6,428,215, which is hereby incorporated byreference in its entirety, the connector 10 can be “tuned” by rotatingthe ferrule 12 relative to the ferrule housing 18 until an optimumrotational position is determined, and then setting the ferrule at the“tuned” or optimum rotational orientation. Connectors are tuned toensure that when two connectors are coupled together via an adapter, theends of the fibers being connected are centered (i.e., aligned) relativeto one another. Poor alignment between fibers can result in highinsertion and return losses. Insertion loss is the measurement of theamount of power that is transferred through a coupling from an inputfiber to an output fiber. Return loss is the measurement of the amountof power that is reflected back into the input fiber.

FIG. 2 shows an example FC connector 30 having a ferrule 32 mountedwithin a ferrule housing 34. A key 36 is fitted over the ferrule housing34. The key 36 is positioned to correspond to a tuned orientation of theferrule 32. An outer grip or connector 38 mounts over the ferrulehousing 34. A hub assembly 40 is fixedly mounted to the ferrule 32. Thehub assembly 40 spring biases the ferrule in a forward direction. Theconnector 30 also includes a dust cap 42 that covers the front of theferrule 32, and a crimp sleeve 37 and boot 44 mounted at the rear of theconnector 30.

In addition to tuning, insertion and return loss can be improved bypolishing the end faces of the ferrules. During the polishing process,the ferrules are commonly held in a fixture, and the end faces arepressed against a rotating polishing wheel or disk. Frequently, the endfaces are polished to form a polished surface oriented along a planethat is perpendicular with respect to the longitudinal axis of thefibers. However, for some applications, the end faces are polished toform a surface aligned at an oblique angle with respect to thelongitudinal axis of the fibers.

Other process steps are also undertaken to complete the manufacture offiber optic connectors. For example, after polishing, the end faces ofthe connector ferrules are often cleaned. Other steps include tuning theconnectors, testing the connectors for insertion and return loss, andassembling the various components of the connectors.

Historically, the manufacture of fiber optic connectors has been quitelabor intensive. Originally, connectors were individually manuallypolished and individually manually moved through the various processingsteps. Manufacturing efficiency improved with the more prevalent use ofmulti-connector fixtures (e.g., see U.S. Pat. No. 6,396,996), whichallowed multiple connectors to be simultaneously processed. Whilemulti-connector fixtures have improved manufacturing efficiencies,further improvements in the area of automation are needed.

SUMMARY

One aspect of the present disclosure relates to equipment havingfeatures adapted to facilitate automating various steps in the processof manufacturing a fiber optic connector.

A variety of advantages of the invention will be set forth in part inthe description that follows, and in part will be apparent from thedescription, or may be learned by practicing the invention. It is to beunderstood that both the foregoing general description and the followingdetailed description are exemplary and explanatory only and are notrestrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate several aspects of the inventionand, together with the description, serve to explain the principles ofthe invention. A brief description of the drawings is as follows:

FIG. 1 illustrates a typical prior art SC connector;

FIG. 2 illustrates another typical prior art FC connector;

FIG. 3 is a schematic diagram of an example embodiment of a connectorprocessing system having features that are examples of inventive aspectsin accordance with the principles of the present disclosure;

FIG. 4 is a schematic diagram of another example embodiment of aconnector processing system having features that are examples ofinventive aspects in accordance with the principles of the presentdisclosure;

FIG. 4A is a schematic diagram of an example polishing station of thesystem of FIG. 4;

FIG. 4B is a schematic diagram of an example cleaning station of thesystem of FIG. 4;

FIG. 4C is a schematic diagram of an example tuning station of thesystem of FIG. 4;

FIG. 4D is a schematic diagram of an example testing station of thesystem of FIG. 4;

FIG. 4E is a schematic diagram of an example SC connector adjust stationof the system of FIG. 4;

FIG. 4F is a schematic diagram of an example FC connector key pressstation of the system of FIG. 4;

FIG. 4G is a schematic diagram of an example dust cap station of thesystem of FIG. 4;

FIG. 5 is a perspective view of an example fixture;

FIG. 6 is a top view of the fixture of FIG. 5;

FIG. 7 is a side view of the fixture of FIG. 5;

FIG. 7A is another side view of the fixture of FIG. 7 with one controlknob in a released position;

FIG. 8 is an end view of the fixture of FIG. 5;

FIG. 9 is an opposite end view of the fixture of FIG. 5;

FIG. 10 is a cross-sectional view taken along line 10-10 of the fixtureof FIG. 6;

FIG. 10A is a cross-sectional view taken along line 10A-10A of thefixture of FIG. 6 with one control knob in the released position;

FIG. 10B is an enlarged view of a portion of the fixture of FIG. 10A;

FIG. 11 is a perspective view of an example stranded bare fiber supportsleeve;

FIG. 12 is an exploded perspective view of the support sleeve of FIG.11;

FIG. 13 is a perspective view of an example cart;

FIG. 14 is a side view of the cart of FIG. 13;

FIG. 15 is a front view of the cart of FIG. 13;

FIG. 16 is a top view of the cart of FIG. 13;

FIG. 17 is a perspective view of the front panel of the cart of FIG. 13;

FIG. 18 is a perspective view of the fixture mount of the cart of FIG.13;

FIG. 19 is a perspective view of an example lead-in conveyor;

FIG. 19A is an enlarged view of a portion of the lead-in conveyor ofFIG. 19;

FIG. 20 is a front view of the lead-in conveyor of FIG. 19;

FIG. 21 is a front view of an example lead-out conveyor;

FIG. 22 is a cross-sectional view of a portion of a fixture conveyor;

FIG. 23 is a perspective view of the fixture conveyor at the polishingstation;

FIG. 23A is an enlarged view of a portion of the conveyor of FIG. 23;

FIG. 23B is an unwrapped view of the portion of the conveyor of FIG.23A;

FIG. 24 is a front view of the conveyor of FIG. 23;

FIG. 24A is an enlarged view of a portion of the conveyor of FIG. 24;

FIG. 25 is a perspective view of an example cleaning station;

FIG. 26 is a perspective view of a portion of the cleaning station ofFIG. 25;

FIG. 27 is a cross-sectional view of a portion of the cleaning stationof FIG. 25;

FIG. 28 is another cross-sectional view of a portion of the cleaningstation of FIG. 25;

FIG. 29 is a side view of an example tuning station;

FIG. 30 is a cross-sectional view of the tuning station of FIG. 29;

FIG. 30A is an enlarged view of a portion of the tuning station of FIG.30;

FIG. 30B is an enlarged view of a portion of the tuning station of FIG.30A;

FIG. 31 is a perspective view of an example adaptor of the tuningstation of FIG. 29;

FIG. 32 is an exploded perspective view of portions of the exampletuning station of FIG. 29;

FIG. 33 is a perspective view of an example testing station;

FIG. 34 is a cross-sectional view of the testing station of FIG. 33;

FIG. 34A is an enlarged view of a portion of the testing station of FIG.34;

FIG. 35 is a perspective view of an example SC connector adjust station;

FIG. 36 is a perspective view of a portion of the SC connector adjuststation of FIG. 35;

FIG. 37 is a cross-sectional view of the SC connector adjust station ofFIG. 35;

FIG. 37A is an enlarged view of a portion of the SC connector adjuststation of FIG. 33;

FIG. 38 is a perspective view of an example FC connector key pressstation;

FIG. 39 is a perspective view of a portion of the FC connector key pressstation of FIG. 38;

FIG. 39A is an enlarged perspective view of a portion of the FCconnector key press station of FIG. 39;

FIG. 40 is a schematic view of an example dust cap station;

FIG. 41 is another schematic view of the dust cap station of FIG. 40with portions of the station removed;

FIG. 41A is an enlarged perspective view of a portion of the dust capstation of FIG. 41; and

FIG. 42 is a cross-sectional view of a portion of the dust cap stationof FIG. 40.

While the invention is amenable to various modifications and alternativeforms, the specifics there have been shown by way of example in thedrawings and will be described in detail below. It is to be understood,however, that the intention is not to limit the invention to aparticular embodiment. On the contrary, the intention is to cover allmodifications, equivalents and alternatives falling within the scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION

In the following detailed description, references are made to theaccompanying drawings that depict various embodiments in which theinvention may be practiced. It is to be understood that otherembodiments may be utilized, and that structural and functional changesmay be made without departing from the scope of the present invention.

I. First Embodiment of Automated Connectorization System

A. System Description

FIG. 3 schematically depicts a fiber optic connector processing system100 having features that are examples of inventive aspects in accordancewith the principles of the present disclosure. The system 100 is adaptedfor use in processing connectorized fiber optic cables 133 (e.g., ribbonor stranded cable). The connectorized cables 133 typically include fiberoptic connectors 135 (e.g., SC connectors, FC connectors, ST connectors,or D4) terminated at first ends of the cables 133, and bare fibers 137(e.g., fibers that have been stripped and cleaved) located at secondends of the cables 133. The bare fibers 137 can be housed within barefiber support sleeves 139 that protect and prevent bending of the barefibers, and also facilitate optically coupling the bare fibers 137 totest equipment during processing of the cables 133. After processing ofthe cables 133, the bare fibers 137 can be used to provide fieldterminations or to provide splices with other cables.

Referring still to FIG. 3, the system 100 includes a plurality ofmodular processing stations arranged in an assembly line configuration.The processing stations shown include a polishing station 110, acleaning station 112, a tuning station 114, a test station 116, an SCconnector adjust station 118, an FC connector key press station 120, anda dust cap installation station 122. The system 100 also includes aconveying system 124 for conveying the connectorized optical cables 133through the various processing stations. One or more processing units(e.g., personal computers or other controllers) can be used to controlthe conveying system 124 and also to control the processes at each ofthe process stations.

The conveying system 124 includes a carrier 126 adapted for carrying anynumber of optical cables 133 ranging from a single optical cable up tohundreds of optical cables. The carrier 126 is shown carrying fixtures132 for securing the connectors 135. The fixtures 132 include clamps 141for holding the connectors 135 as the connectors are processed at thevarious processing stations. The clamps 141 preferably hold theconnectors 135 with ferrules 145 of the connectors exposed so that endfaces 147 of the ferrules 145 can be readily accessed for processing.The fixtures 132 also include receiver sockets 143 for receiving thebare fiber support sleeves 139. When mounted within the receiver sockets143, the ends of the bare fiber support sleeves 139 are exposed tofacilitate optically coupling the bare fibers 137 to test equipmentduring processing. The fixtures of the carrier 126 are preferablyadapted to hold a plurality of connectors 135 during processing. In onenon-limiting embodiment, the fixtures of the carrier can have a capacityof least 72 connectors 135.

The stations are preferably standalone units that are assembled togetherto form the assembly line. The modularity of the stations allows thestations to be readily removed, added, or rearranged along the assemblyline. For example, each station can include wheels to allow for ease inthe rearrangement of the different stations. While seven stations havebeen shown in the embodiment of FIG. 3, it will be appreciated thatadditional stations can be added, certain stations can be removed,and/or the order of the stations can be changed without departing fromthe principles of the present disclosure.

B. Description of System Operation

In use, the carrier 126 initially conveys the connectorized opticalcables 135 to the polishing station 110. The polishing station 110preferably includes a plurality of substations each corresponding to adifferent polishing function. For example, the polishing substations canbe configured with polishing mediums (e.g., films, disks, etc.) ofdifferent coarseness, and polishing pads of differing durometers, toachieve different polishing functions.

The polishing station 110 can include one or more drive mechanisms formoving the polishing mediums relative to the ferrule end faces 147 ofthe connectors 135 being processed. For example, the drive mechanismscan spin, oscillate or otherwise move the polishing mediums relative tothe ferrule end faces 147. Alternatively, the end faces 147 of theconnectors 135 can be moved relative to the polishing mediums. Thepolishing mediums and/or ferrules 145 of the connectors 135 can bebiased to maintain contact between the end faces 147 and the polishingmediums.

After the ferrule end faces 147 of the connectors 135 have beenpolished, the carrier 126 conveys the connectorized cables 133 to thecleaning station 112. At the cleaning station 112, residue or otherforeign material deposited on the ferrules 145 of during the polishingstage is preferably removed. In one embodiment, steam and blasts of air(e.g., carbon dioxide) can be used to clean the ferrules 145.

After cleaning, the carrier 126 conveys the fixtures 132 to the tuningstation 114. At the tuning station 114, the connectors 135 (e.g., SC andFC connectors) are tested for insertion and/or return loss at variousincremental rotational positions (e.g., 60 degree increments). Theconnectors 135 are tuned by inputting light into the connectors 135 ateach rotational increment, and comparing the relative amount of lightthat is output from the bare fiber ends 137 at each increment. Therotational orientation of the tuned position (i.e., “the key location”)is selected to ensure that when two connectors are optically coupledtogether, the ferrules of the coupled connectors are relatively orientedto provide optimum optical performance. After tuning, FC connectors canbe rotated within the fixtures to place the key locations at knownrotational positions that are coordinated with subsequent processingsteps (e.g., the key press step at the FC connector key press station120). Alternatively, in the case of SC connectors, the key locations canbe stored in memory for use at the SC connector adjust station 118.

From the tuning station 114, the carrier 126 moves the connectorizedcables 133 to the test station 116. At the test station 116, each of theconnectors 135 is tested for insertion loss and return loss to ensureeach of the connectors complies with predetermined insertion loss andreturn loss standards. The connectors 135 are tested by inputting lightthrough the connectors 135 and measuring the quantity of light outputthrough the bare fiber ends 137. Information concerning connectorfailure is stored in memory for use during subsequent processingoperations.

If SC connectors are being processed, the carrier 126 moves from thetest station 116 to the SC connector adjust station 118. If FCconnectors are being processed, the carrier 126 moves from the teststation 116, past the SC connector adjust station 118, to the FCconnector key press station 120. If ST or D4 connectors are beingprocessed, the carrier moves from the test station 116, past both the SCconnector adjust station 118 and the FC connector key press station 120,to the dust cap station 122.

At the SC connector adjust station 118, the ferrule of each SC connector(e.g., hub assembly 20 of SC connector 10 shown in FIG. 1) is rotatedrelative to its corresponding ferrule housing (e.g., housing 18) untilthe keys of the ferrule housings align with the key locations previouslydetermined at the tuning station 114 and stored in memory. After the SCconnector adjustment process has been completed, the carrier 126 carriesthe SC connectors past the FC connector key press station 120 to thedust cap station 122.

At the FC connector key press station 120, keys (e.g., key 36 of FCconnector 30 shown in FIG. 2) are pressed on to the bodies of FCconnectors at the key mounting locations. The pre-orientation of therotational positions of the FC connectors at the tuning station 114ensures that the keys are properly oriented at the optimal tuned or keylocations. Thereafter, the carrier 126 moves the FC connectors to thedust cap station 122.

At the dust cap station 122, dust caps (e.g., dust cap 42 shown in FIG.2) are pressed over the ferrules of the connectors. In some embodiments,dust caps are only applied to those connectors that were successfullyprocessed through system 100. For example, dust caps can be placed ononly those connectors that receive a passing rating at test station 116.In this manner, during subsequent processing, the presence of a dust capindicates that the connectors are ready for subsequent processing (e.g.,installation of the outer grips). The absence of a dust cap alerts theoperator that the connector has failed in some respect, and alerts theoperator to remove the connector for re-processing.

II. Second Embodiment of Automated Connectorization System

A. System Description

FIGS. 4 and 4A-4G show an alternative fiber optic connector processingsystem 200 having features that are examples of inventive aspects inaccordance with the principles of the present disclosure. The system 200includes a plurality of modular processing stations arranged in anassembly line. Similar to the previous embodiment, the processingstations include a polishing station 210, a cleaning station 212, atuning station 214, a test station 216, an SC connector adjust station218, an FC connector key press station 220 and a dust cap station 222,all of which are described further below.

The system 200 also includes a cart conveying unit 224 for conveying acart 226 from station to station. See FIGS. 13-18 and accompanyingdescription below. The cart 226 is adapted for carrying one or moreconnectorized fiber optic cables 133.

The system 200 further includes fixture assemblies 300 that can bemounted to and detached from the cart 226. See FIGS. 5-10B andaccompanying description below. For clarity, only a few of the fixtureassemblies 300 are shown mounted to the cart 226. The fixture assemblies300 each include a tuning and test fixture 302 for clamping boots 149 ofthe connectors 135, and a polishing fixture 304 having nests forsupporting the ferrules 145 of the connectors 135. The tuning and testfixtures 302 also define receptacles 342 for receiving the bare fibersupport sleeves 139 mounted to bare fiber ends 137 of the cables 133.

The system 200 further includes a fixture conveyor 240 for conveying thefixture assemblies 300 from station to station along the assembly line.See FIGS. 19-24A and accompanying description below. The fixtureconveyor 240 is a separate conveyor from the cart conveyor 224. However,the operation of the fixture conveyor 240 is coordinated with theoperation of the cart conveyor 224 such that the fixture assemblies 300and their corresponding cart 226 move in a side-by-side relationshipfrom station to station.

The system 200 includes a main system controller 250 that coordinatesthe operation of the fixture conveyor 240 with the operation of the cartconveyor 224. The main system controller 250 interfaces with controllersat each of the stations to integrate each station into the overallsystem. In certain embodiments, the main systems controller 250 caninclude a personal computer with keyboard access.

B. System Operation Overview

In general use of the system 200, a spool 260 of fiber optic cable 133is placed on the cart 226 while the cart is off-line from the cartconveyor 224. Connectors 135 of the fiber optic cables 133 are thenclamped within the fixture assemblies 300, and the bare fiber supportsleeves 139 are inserted within receptacles 342 defined by the fixtureassemblies 300. The fixture assemblies 300 are then secured to the cart226.

After securing the fixture assemblies 300 to the cart 226, the cart 226is manually wheeled to the cart conveyor 224. The cart 226 then engagesthe cart conveyor 224 and is conveyed toward the polishing station 210.Prior to reaching the polishing station 210, the fixture assemblies 300are disconnected from the cart 226 and engaged with the fixture conveyor240. The fixture conveyor 240 then conveys the fixture assemblies 300 tothe polishing station 210 for polishing of the ferrules 145.

At the end of the polishing station, the polishing fixtures 304 offixture assemblies 300 are stripped from the tuning and test fixtures302 to provide more ready access to the connectors 135 during subsequentprocessing steps. The tuning and test fixtures 302 are then moved by thefixture conveyor 240 to subsequent processing stations to allow theconnectors 135 to be processed (e.g., cleaned, tuned, tested, keyadjusted, key pressed, fitted with dust caps or processed by otherprocessing operations).

Typically, the tuning and test fixtures 302 are stopped at stationswhere processing is desired to provide sufficient time for processing.As described with respect to the embodiment of FIG. 3, depending on thetype of connector being processed, certain of the stations may beby-passed. The functions performed at each of the stations can besimilar to those described with respect to the embodiment of FIG. 3.

Movement of the cart 226 is preferably coordinated with the movement ofthe fixture on the conveyor 240. The conveyor 240 preferably moves thefixtures in a stepwise motion (i.e., the movement is indexed or steppedin fixed increments). The cart conveyor 224 preferably moves the cart226 in a stepwise motion that corresponds to the stepwise motiongenerated by the conveyor 240. In this manner, the fixtures 300 (whichcarry the connectors 135) and the cart 226 (which carries the bulk ofthe cable 133) remain in a side-by-side relationship throughout thevarious processing steps.

After the dust cap station 222, the fixtures 302 are disengaged from theconveyor 240 and re-connected to the cart 226, and the cart 226 isdisengaged from the cart conveyor 224 and manually wheeled to a locationfor further processing of the connectors 135. For example, at asubsequent location, outer grips can be pressed on the connectors 135.Thereafter, the connectors 135 can be removed from the fixtures 302, andthe fixture assemblies 300 can be re-assembled and reloaded with a nextbatch of connectors 135. The cart 226 can then be wheeled back to thestart of the cart conveyor 224 to initiate processing of the next batchof connectors 135.

A plurality of carts 226, each including a plurality of connectors 135mounted in fixture assemblies 300, can be processed by system 200. Forexample, a plurality of carts 226 can be sequentially loaded into system200 so that each station of system 200 is eventually occupied at a givenpoint in time.

C. System Component Descriptions

a. Fixture Assemblies

Referring now to FIGS. 5-10B, the fixture assemblies 300 of the system200 each include the tuning and test fixture 302 as well as thepolishing fixture 304. The polishing fixture 304 is detachably mountedto the underside of the tuning and test fixture 302. A latchingarrangement, such as a pair of spring latches 306, is used to secure thepolishing fixture 304 relative to the tuning and test fixture 302. Thepolishing fixture 304 also includes alignment pins 308 that fit withinopenings 309 defined by the tuning and test fixture 302 to maintainalignment between the two fixtures 302, 304. See FIGS. 10 and 10A.

Referring to FIGS. 8 and 9, each of the spring latches 306 includes apair of resilient arms 310 secured to the polishing fixture 304. Theresilient arms 310 are biased together and interlocked with a retainingmember 312 provided on the tuning and test fixture 302. The polishingfixture 304 can be detached from the tuning and test fixture 302 bypulling downwardly on the polishing fixture 304 with sufficient force toflex the arms 310 of the latches 306 apart such that the arms 310disengage from the retaining member 312.

The polishing fixture 304 of the fixture assembly 300 includes threeferrule nests 314 sized to receive ferrules 145 of the connectors 135.See FIGS. 10, 10A, and 10B. The ferrules 145 protrude downwardly beyondthe nests 314 such that the end faces 147 of the ferrules 145 areexposed for polishing. In addition, the ferrule nests 314 form a closetolerance fit as the ends 147 of ferrules 145 extend below the fixture304.

Each ferrule nest 314 also includes a boss 319 with end 317. See FIG.10B. The boss 319 functions to center the ferrule 145 of each connector135 and is sized so that the end 147 of the ferrule 145 for both FCconnectors and SC connectors extends an equal distance below the fixture304. Specifically, as shown in FIG. 10B, ends 317 of boss 319 extendinto and contact housing 18 of SC connector 135 a. In contrast, an end311 of housing 34 of FC connector 135 b contacts the base of the nest314. In this manner, end faces 147 of both the SC connector 135 a and FCconnector 135 b extend an equal distance below fixture 304.

As shown in FIGS. 4, 6, and 10, the polishing fixture 304 also includesan extension 316 that extends beyond the end of the tuning and testfixture 302. The extension 316 provides a location where the polishingfixture 304 can be clamped by a polishing machine at the polishingstation 212.

Referring to FIG. 8, the tuning and test fixture 302 includes an endopening 315 for receiving retractable retention pins of the cart 226(see FIG. 18) to mount the fixture assembly to the cart 226. The tuningand test fixture 302 also includes a V-notch 320 (see FIGS. 6 and 7) forinterlocking with resilient retention clips provided on the cart 226.The clips interlock with the V-notches 320 to prevent the fixtureassemblies 300 from inadvertently rotating on or disengaging from themounting pins of the cart 226.

The tuning and test fixture 302 also include three clamps 230 (bestshown in FIGS. 5, 7, 10, 10A, and 10B) adapted for clamping boots 149 ofthe connectors 135 to hold the connectors 135 during processing. Each ofthe clamps 330 includes two clamp members 331 between which the boots149 of the connectors 135 are clamped. Each of the clamp members 331includes a recessed mid-region 333. The recessed mid-region 330 definesreceptacles (e.g., channels or slots) in which the boots 149 of theconnectors 135 can be clamped. The recessed mid-regions 333 havegenerally V-shaped cross-sections with the widths of the recessedmid-regions 333 enlarging as the recessed mid-regions 333 extend in adownward direction. A pair of resilient members 335 (e.g., O-rings) ismounted within each mid-region 333. The resilient members 335 facilitategripping the boots 149 of the connectors 135.

The clamp members 331 are spring biased toward one another (i.e., towarda clamped orientation). The clamp members 331 can pivot slightly toaccommodate connectors with boots of differing dimensions and tapers.See, for example, FIG. 10B, which illustrates clamp members 331 clampedto boot 28 of SC connector 135 a and boot 44 of FC connector 135 b. Inaddition, when the clamp members 331 are moved from the closed to theopen position, the clamp members 331 move slightly in an upwarddirection during the beginning of movement to the open position so thattension on the connector 135 is released prior to release of the boot ofthe connector.

The tuning and test fixture 302 further includes clamp control knobs 355for manually opening and closing the clamps 230. In manual operation, asillustrated in FIGS. 7A and 10A, control knob 355 a is pulled away fromfixture 302 to open the clamp 230 a to allow a connector 135 to beinserted into or removed from clamp 230 a. Knob 355 a can be rotated aquarter turn to temporarily lock clamp 230 a in the open position. In anautomatic operation, internal components of fixture 302 can be actuatedto open clamps 230 a, 230 b, and 230 c without requiring control knobs355 a, 355 b, and 355 c to be manually pulled upward.

The tuning and test fixture 302 further includes a receiver 340 definingthe receptacle 342 for receiving one of the bare fiber support sleeves139, which is illustrated in FIGS. 11 and 12 and described furtherbelow. The receiver 340 extends through the main body of the tuning andtest fixture 302 and includes a lower portion that is accessible fromthe underside of the main body 302. See FIG. 10A. When the bare fibersupport sleeve 139 is mounted within the receiver 340, the ends of thebare fibers are accessible from the underside of the tuning and testfixture 302 for allowing the fibers to be optically connected to a teststructure such as a remote test head for use in insertion loss andreturn loss testing.

The tuning and test fixture 302 further includes upper and lower pins344 and 346. See FIGS. 7 and 10. The upper pin 344 projects upwardlyfrom the main body of the fixture 302, and the lower pin 346 projectsdownwardly from the main body of the fixture 302. The pins 344, 346 areadapted to engage the fixture conveyor 240. See FIG. 22.

As shown in FIGS. 11 and 12, the bare fiber support sleeves 139 includea top portion 151 that is pivotally mounted to a base portion 152. Afiber holder 156 including ferrules 153 is configured to receive andhold stranded bare fiber. In use, bare stranded fiber is extendedthrough channel 154 formed in base portion 152 and into fiber holder156. Previously stripped ends of the stranded fiber are positioned toextend through ferrules 153. Then, the top portion 151 is pivoted towardthe base portion 152 until in the position illustrated in FIG. 11. Next,the stripped ends of the fibers that extend from ferrules 153 arecleaved. In one embodiment, a cleaver having product no. CT-107,manufactured by Fujikura Ltd. of Tokyo, Japan, is used to cleave thestriped fiber. Once the fibers are cleaved, the bare fiber supportsleeve 139 is positioned in the tuning and test fixture 302, as shown inFIGS. 5, 7, and 10A. In this position, the ferrules 153 of supportsleeve 139 are accessible below the fixture 302.

If, instead of stranded fiber, ribbon fiber is being processed, asimilar support sleeve can be used. However, for ribbon fiber, noferrules are required because the ribbon structure provides adequatesupport for the fibers. In addition, for ribbon fiber, the fiber can beboth stripped and cleaved once the fiber has been placed in the supportsleeve.

b. Cart Assembly

FIGS. 13-18 show various views of the cart 226. The cart 226 includes abase 400. A rear portion of the base 400 defines a platform 402 forsupporting a spool of fiber optic cable. Rollers 403 are provided on theplatform 402 for facilitating loading and unloading spools of fiberoptic cable to or from the platform 402. The sides of the platform 402are enclosed by side walls 404 and the front of the platform 402 isenclosed by a front wall 406. The back of the platform 402 is open tofacilitate loading fiber optic spools onto the platform. Handles 408 areprovided at the top sides of the side walls 404 for facilitatingmaneuvering of the cart 226.

With respect to the spools carried by the cart 226, the spools typicallyrange in diameter from 12 inches 36 inches. The spools can carryanywhere from one fiber optic cable to hundreds of fiber optic cables.In the case where a large number of fiber optic cables are wrapped aboutthe spool, the fibers are typically bundled within one or more bundlingsheathes. Sub-bundles can be provided within the main sheathed bundles.The fiber optic cables can range in length from a few feet to hundredsof feet. While the cables will typically be provided on spools, it willbe appreciated that for short length cables, spools may not be needed.

Referring to FIGS. 13-16, casters 410 are mounted to the underside ofthe base 400. The casters 410 include pivoting caster wheels 412. Thecaster wheels 412 include central grooves 414. See FIG. 14. A pair ofracks or ladders 416 is also mounted to the underside of the base 400.The ladders 416 provide structure for allowing the cart conveyor 224 toengage the cart 226.

The cart 226 further includes a front cable management structure 420that projects forwardly from the front wall 406. The cable managementstructure 420 includes an upright front panel 422. See FIGS. 13, 15, and17. Cable management structures such as spools 424 for managing excesscable and clamps 426 for clamping cables are mounted to the front panel422. Two cable clamps 428 are mounted to the top of the upright panel422. The clamps 428 are adapted for clamping a sheathed portion of abundle of fiber optic cables. The sheathed portion of the bundles ispreferably clamped at the clamps 428, and extensions of the fiber opticcables bundled within the sheath are typically fanned downwardly fromthe clamps 428 with connectorized ends 135 of the fiber optic cablesbeing clamped within the fixture assemblies 300. Excess length of cablecorresponding to the connectors being processed, as well as extra cableshaving connectors that have already been processed or are soon to beprocessed, can be managed by wrapping such cables around the spools 424.

The cart 226 further includes a fixture mount 450. See FIGS. 14 and 18.The fixture mount 450 includes a plurality of mounting pins 452 adaptedto be received within the rear openings 315 of the tuning and testingfixtures 302. The depicted mount 450 is adapted for mounting 24 fixtureassemblies 300. However, it will be appreciated that the capacity of themount 450 can be varied without departing from the principles of thedisclosure.

The fixture mount 450 also includes resilient retention clips 454 thatengage the notches 320 in the tuning and test fixtures 302 to preventthe fixtures 302 from inadvertently disengaging from the pins 452. Thefixture mount 450 further includes a handle 456 for retracting thefixture mount 450 to disengage the fixture assemblies 300 from the cart226 after the fixture assemblies 300 have been engaged by the fixtureconveyor 240. By pivoting the handle 456, the pins 452 are withdrawnfrom the rear openings 315 of the tuning and test fixtures 302 todisengage the fixture assemblies 300 from the cart 226. As the fixturemount 450 is retracted, the retaining clips 454 flex upwardly to allowthe fixture assemblies 300 to be disengaged from the cart 326.

The cart 226 further includes a bin 460 for receiving and storing thepolishing fixtures 304. See FIG. 14. As will be described below, afterthe polishing processes have been completed at the polishing station212, the polishing fixtures 304 are stripped from the tuning and testfixtures 302. After the polishing fixtures 304 have been stripped, thepolishing fixtures 304 slide by gravity down a ramp and into the bin 460for storage. Subsequently, the polishing fixtures 304 are removed fromthe bin 460 and recoupled to fixtures 302 for processing the next batchof connectors.

c. Cart Conveyor

The cart conveyor 224 is depicted in FIG. 4 as including a pair ofparallel tracks 600 for receiving the caster wheels 412 of the cart 226.Center guides 602 are located within each of the tracks 600. When thecart 226 is conveyed along the tracks 600, the grooves 414 of the wheels412 ride along the center guides 602. The cart conveyor 224 alsoincludes a drive mechanism for moving the cart 226 along the tracks 600.It will be appreciated that the drive mechanism can have any number ofdifferent configurations. In the depicted embodiment, the drivemechanism includes a pneumatically powered walking beam drive 661. Inother embodiments, the drive mechanism can include a chain drive, astepper motor drive, a rack and pinion drive, or any other drivesuitable for conveying the cart in a controller manner.

The walking beam drive 661 includes a pair of parallel beams 662 a, 662b having lugs 663 for engaging the ladders 416 on the underside of thecart 226. Vertical pneumatic cylinders 665 raise and lower the beams 662a, 662 b and horizontal pneumatic cylinders 667 move the railshorizontally. The left beam 662 a is preferably moved in a squarepattern. For example, beam 662 a is raised (e.g., by cylinders 665) suchthat the lugs 663 engage the left ladder 416 of the cart 226, is movedhorizontally forward (e.g., by cylinder 667) to move the cart 226forward one increment, is lowered (e.g., by cylinders 665) to disengagethe lugs 663 from the cart 336, and is then horizontally returned to itsinitial position (e.g., by cylinder 667) where it is ready to repeat thecycle. The right beam 662 b can be moved in a similar pattern.

Alternatively, the beam 662 b can simply be raised and lowered toselectively engage right ladder 416 the cart 226. For example, the rightbeam 662 b can be raised when the left beam 662 a is lowered to preventunintentional movement of the cart 226, and then lowered when the lugs663 of the left beam 662 a are in engagement with the cart 226.

d. Fixture Conveyor

Referring now to FIGS. 4 and 19-24A, the fixture conveyor 240 is shownincluding two generally parallel guide rails 700 and two generallyparallel screw drives 702. The screw drives 702 can be powered by adrive mechanism 707 (see FIG. 21) such as a pneumatic drive, aservo-motor drive, or any other drive suitable for rotating the screwdrives 702. The screw drives 702 are vertically offset from one another(i.e., set at different elevations) such that one of the screw drives702 is adapted to engage the upper guide pins 344 of the fixtures 302,and the other of the screw drives 702 is adapted to engage the lowerpins 346 of the fixtures 302. See FIGS. 20, 21, and 22.

As shown in FIG. 22, the pins 344, 346 ride within slots 703 definedwithin the screw drives 702. By rotating the screw drives 702, thefixture 300, including the tuning and test fixture 302 and polishingfixture 304, is conveyed along the screw drives 702.

The slots 703 of the screw drives 702 are generally arranged at anangled pitch configuration 709 for ⅔ of a turn and then a non-angledconfiguration 701 for the remaining ⅓ of the turn. See FIGS. 23A and23B. This configuration results in the fixture assemblies 300 beingconveyed along the screw drives 702 for ⅔ of the turn (i.e., in angledpitch 709) and then dwelling at one spot for ⅓ of the turn (i.e., innon-angled configuration 701) for each revolution of the screw drives702. The dwell times provided by the non-angled portions 701 of theslots 703 assist in preventing inertial bumping of the fixtures duringconveying, as well as allow the screw drives 702 to reengage the fixture300 after each polishing cycle, as described further below.

In one embodiment, the fixtures 300 are moved about 1 inch perrevolution of the screw drives 702 and are typically moved in 2 inchincrements between processing steps. To correspond with the fixtureconveyor 240, the cart conveyor 224 preferably moves the cart 226 in thesame 2 inch increments. While 2 inch increments are preferred, it willbe appreciated that the size of the increments can be varied withoutdeparting from the principles of the disclosure.

As shown at FIGS. 23, 24, and 24A, the screw drives 702 also preferablyinclude flat regions 348 located at the polishing station 210. The flatregions 348 are positioned to correspond with the non-angled portions701 of the slots 703. The flat regions 348 allow the pins 344, 346 ofthe fixtures 302 to be disengaged from the screw drives 702 duringpolishing operations, as described further below. After polishing, thenon-angled portions 701 of the slots 703 allow the pins 344, 346 to bereengaged with the screw drives 702 upon revolution of the screw drives.

The screw drives 702 also include regions of increased slot pitch 705before and after entering the flat regions 348 of the polishing station210. See FIG. 24A. The increased pitch regions 705 provide an increasedspacing between the group of fixtures 300 being polished at thepolishing station 210, and fixtures 300 located before and after thepolishing station 210. This spacing allows the group of fixtures 300 atthe polishing station 210 to be moved longitudinally during polishingwithout contacting adjacent fixtures.

While a screw drive arrangement is preferred for conveying the fixtures,it will be appreciated that other types of drive mechanisms such as rackand pinion drives, chain drives, belt drives or other drives could alsobe used.

The screw drives 702 can be powered by a drive mechanism 707 such as oneor more servo-motors. If a single servo-motor is used, belts or othertorque transfer arrangements can be used to transfer torque from theservo to the screw drives 702 for turning the screw drives 702.

The fixture conveyor 240 can also include a lead-in section 708 and alead-out section 709. See FIGS. 19-21. The lead-in and lead-out sections708, 709 preferably have a length generally equal to at least one cartlength. At the lead-in and lead-out sections 708, 709, straightlongitudinal slots 349 can be formed in screw drives 702 to allow pins344, 346 of fixtures 300 to slide therein, thereby facilitating engagingthe fixture pins 344, 346 with the screw drives 702 as the cart 226 islead into the assembly line, and to facilitate disengaging the fixturepins 344, 346 from the screw drives 702 as the cart 226 is lead out ofthe assembly line. See FIG. 19A.

e. Polishing Station

Referring to FIGS. 4 and 4A, the depicted polishing station 210 includesa plurality of polishing substations 210 a-210 g. Each substationincludes three polishing pads 750 that can be individually raised andlowered by separate lift mechanisms (e.g., pneumatic cylinders).Polishing films are positioned between the pads 750 and the ferrule endfaces 147 of the ferrules 145 nested within the polishing fixtures 304of the fixture assemblies 300.

By lifting the polishing pads 750, the polishing films are pressed intocontact with the ferrule end faces 147. The various polishingsubstations 210 a-210 g can provide various polishing functions. Forexample, the substation 210 a can provide an epoxy and hackle removalfunction. Later substations can provide radius and apex shapingfunctions.

The substations can utilize polishing films having increasingly finegrit sizes to provide the final polished end faces. The substations canprovide a chemical mechanical polishing effect by using polishing filmshaving reactive components. An example film material includes ceriumoxide. Example polishing steps are disclosed in U.S. Pat. No. 6,599,030to Millmann, which is hereby incorporated by reference.

The polishing station 210 can include a fluid injection system forcleaning the polishing films between polishing cycles. For example, thefluid injection system can include one or more jets that spraysde-ionized water interspersed in a stream of high-pressure air to removedebris and other unwanted particles from the polishing films.

The polishing station 210 also includes a drive mechanism 755 for movingthe fixture assemblies 226 along a horizontal plane relative to thepolishing films. The drive mechanism 755 can include an X-Y table. Acontroller 756 can be used to program the polishing mechanism 755 tomove or oscillate the fixture assemblies 300 along predeterminedpolishing patterns. The drive mechanism 755 includes clamps 757 adaptedto clamp on the extensions 316 of the polishing fixtures 304 to securethe fixture assemblies 300 to the drive mechanism 755. The drivemechanism 755 preferably simultaneously moves all of the fixtureassemblies 300 at the polishing station 210 along the preprogrammedpolishing pattern.

Further details regarding aspects of the polishing system can be foundin U.S. patent application Ser. No. 10/356,358 to Bianchi, filed on Jan.31, 2003 and entitled “Apparatus and Method for Polishing a Fiber OpticConnector,” which is hereby incorporated by reference.

In operation of the polishing station 210, the fixture assemblies 300are moved from substation to substation by the screw drives 702. Whenthe fixture assemblies 300 reach each substation, the clamp 757corresponding to the given substation clamps down on the extension 316of the polishing fixture 304. When the fixture assemblies 300 arealigned with the substations, the screw drives 702 are positioned withthe flats 348 oriented to not interfere with the fixture pins 344, 346.See FIGS. 24 and 24A. Therefore, the drive mechanism 755 can readilymove the fixture assemblies 300 without interference from the screwdrives 702. After a polishing sequence has been completed, the clamps757 are released, the screw drives 702 are rotated, causing the pins344, 346 to re-engage the slots 703, and the fixture assemblies 300 aremoved to the subsequent polishing substation. Thereafter, the process isrepeated until the polishing process is complete.

When the fixtures are moved along the fixture conveyor 240, the fixtures300 ride along guide rails 700. As shown, for example, at FIGS. 7, 10,and 22, the guide rails 700 are adapted to ride against shoulderportions 321 of the tuning and test fixture 302 such that a mid-portionof the test and tuning fixture 302 is captured between the rails 700.The rails 700 include portions that pivot about points 710 located atthe polishing station 210 (see FIGS. 24 and 24A). During polishing, theportions of rails 700 pivot about points 710 outwardly toward thecorresponding screw drives 702 to provide clearance for allowing thefixtures 300 to be moved laterally by the drive mechanisms of 755 alongthe desired polishing pattern.

A stripping substation 760 is located at the end of the polishingstation 210. At the stripping station 760, the polishing fixtures 304are pulled downwardly from the tuning and test fixtures 302 to disengagethe polishing fixtures 304 from the tuning and test fixtures 302 (e.g.,by pulling downwardly on the polishing fixture 304 with sufficient forceto flex the arms 310 of the latches 306 apart such that the arms 310disengage from the retaining member 312, as shown in FIGS. 8 and 9).Once disengaged, the polishing fixtures 304 slide via gravity down aramp into the storage bin for 460 of the cart 226. See FIG. 14. Byremoving the polishing fixture 304, improved access is provided to theconnectors 135 for subsequent processing. Since the connectors areclamped at the boot 149, the lower ends of the connectors 135 are fullyexposed and readily accessible from under the tuning and test fixtures302.

f. Cleaning Station

Referring to FIGS. 4, 4B, and 25-28, the cleaning station 212 includessubstations 212 a, 212 b for cleaning the ferrule end faces 147 of theconnectors 135. The substation 212 a includes steam recesses 790 intowhich the lower ends of the connectors 135 are inserted to expose theferrules 145 to cleansing steam. Steam is provided to the steam recesses790 by nozzles 791 that are connected to a steam source, and dry air isprovided by nozzles 797. The substation 212 b includes air streamrecesses 795 into which the lower ends of the connectors 135 areinserted. The air stream recesses 795 are pneumatically coupled to asource of compressed gas. The source of compressed gas provides apressurized gas stream to the recesses for cleaning the ferrules 145. Inone embodiment, the pressurized gas includes carbon dioxide. Operationof the cleaning module 212 can be controlled by a controller 799 thatinterfaces with the main system controller 250.

In use, the fixture conveyor 240 advances a fixture 302 to substation212 a and the fixture stops at a position where the connectors 135 alignwith the steam recesses 790. The substation 212 a is then actuatedtowards the fixture 302 until end faces 147 of the connectors 135 arepositioned to extend into the recesses 790. See FIG. 27. Steam (seearrows S) is applied to the ferrules 145 of the connectors 135 bynozzles 791, and dry air is applied by nozzles 797 (see arrows A). Oncethe steam cleaning process is complete, fixture 302 is indexed to thesubstation 212 b, where the connectors 135 are cleaned with air in asimilar manner.

Referring to FIG. 28, in one embodiment, an air seal is used to seal thesubstations 212 a, 212 b when cleaning the connectors 135. When steam,illustrated by arrows S, is applied to the end faces 147 of connector135 during cleaning at substation 212 a, air is forced through passage792 and out recess 790 surrounding the connector 135 (see arrows B). Theair that is forced through passage 792 and out of recess 790 acts as abarrier to the steam and other debris removed from end faces 147 fromexiting the substation 212 a. In this manner, the portions of connector135 located outside of the substation 212 a are maintained in a cleancondition.

After the air cleaning, the fixture 302 is moved to the tuning station214.

g. Tuning Station

Referring to FIGS. 4, 4C, and 29-32, the tuning station 214 includesthree master tuning connectors 800 and a remote test head 806 for use ininputting light into the connectors 135, and monitoring the light outputthrough the bare fiber ends 137 held within the support sleeves 139. Thetuning connectors 800 can be raised and lowered by a lift mechanism 802,and individually rotated by rotational drives 803. A conventionaloptical testing apparatus 808 is optically connected to the mastertuning connectors 800 and the remote head 806. In one embodiment, thetesting apparatus 808 includes a light member frame having product no.8163A, a laser light source having product no. HP 81654A, a light meterhaving product no. 81618A, and a remote head having product no. 91623A,all being manufactured by Agilent Technologies of Palo Alto, Calif. Inaddition, a fiber optic switch (not shown) is used to switch the lightsignals entering the testing apparatus 808 so that the testing apparatus808 can be used for all three master tuning connectors 800.

Intermediate adapters 860 are positioned between the tuning connectors800 and the connectors 135 being processed. See FIGS. 30B and 31. Theadapters 860 include a boss 813 that surrounds a split sleeve 861 sizedto receive the ferrules of the tuning connector 800 and connector 135. Aclamp 862 provides a compression force on the lower portion of the splitsleeve 861 to retain the ferrule of the tuning connector 800 in thesplit sleeve 861 of the adapter 860.

A module controller 810 interfaces with the testing apparatus 808 andvarious other components to control operation of the station 214. Themodule controller 810 also interfaces with the with the main systemcontroller 250. In addition, a machine controller 811 interfaces withthe structural components of the station 214 to control movement of thevarious components of the station 214, such as lift mechanism 802 androtational drives 803.

In use of the tuning station 214, the screw drive 702 conveys a fixture302 to a position where the connectors 135 held by the fixture 302 arepositioned directly above corresponding master tuning connectors 800. Analignment mechanism 814 is used to align the fixture 302 with respect tothe station 214, and an alignment mechanism 809 is provided forretaining the ferrules of the connectors in direct alignment with themaster tuning connectors 800. See FIG. 32. For SC connectors, fingers819 are included on alignment mechanism 809 to prevent rotation of theconnectors 135 during tuning.

Once the ferrules of the connectors 135 are aligned over the tuningconnectors 800, the tuning connectors 800 are raised to provide opticalconnections with the connectors being processed. Adapters 860 providethe connection between the tuning connectors 800 and the connectors 135being processed. The bare fiber ends held within the support sleeve 139mounted within the receiver 342 of the fixture 302 are also opticallycoupled to the remote head 806.

Once the connectors 135 and the bare fiber ends 137 have been coupled tothe test apparatus 808 respectively by the tuning connectors 800 and theremote head 806, the test apparatus 808 injects light through the tuningconnectors 800 and into the connectors 135 being processed. From theconnectors 135, the light travels through the optical fibers to whichthe connectors 135 are terminated and exits the fibers through the barefiber ends 137 into the remote head 806. In this manner, by detectingthe amount of light that is transferred from the connectors 135 to thebear ends 137 of the fibers, the testing unit 808 can determine theinsertion loss or return loss rating for the connectors 135.

After testing the connectors 135 at a first rotational orientation, themaster tuning connectors 800 are lowered by the lift mechanism 802,rotated an increment (e.g., 60 degrees) by the rotational drives 803,and then raised back up by the lift mechanism 802 to reconnect thetuning connectors 800 with the connectors 135. The testing device 808 isthen used to test the connectors at the second rotational position. Thisprocess is repeated a plurality of times until each of the rotationalpositions of the connectors 135 have been tested for tuning purposes.

After this process has been completed, the various readings are comparedto determine the appropriate key location. For SC connectors, the keylocations of each of the connectors are stored in memory. For FCconnectors, the boots 149 of the connectors 135 are released from thefixture clamps 330 while the connectors 135 remain in sleeves 861 ofadapters 860. The rotational drives 808 are then used to turn the mastercables 800 and associated adapters 860, which in turn causes theconnectors 135 to individually rotate. Each connector 135 is rotateduntil the connector 135 is located at the tuned orientation, which iscoordinated with subsequent processing at the FC connector key pressstation 270. The fixture clamps 330 are then reengaged on boots 149 ofthe connectors 135 to maintain the connectors 135 in the desiredrotational orientation.

h. Test Station

Referring now to FIGS. 4, 4D, and 33-34A, the test station 216 includesa master test connector 850 that is moved up and down by a liftmechanism 851 and moved laterally by a lateral drive mechanism 853. Thetest station 216 also includes a test unit including a remote test head855 that optically couples to the bare fiber ends of the connectors 135held by the fixture 302. In one embodiment, the test unit 859 is anIQS-510P Industrial PC including an IQS-1700 laser, an IQS-3250 lightmeter, and an OHS-1700 remote head, all manufactured by EXFO of Quebec,Canada. The test station 216 further includes a fiber optic testingdevice 859 optically coupled to the master test connector 850 and theremote test head 855. A controller 891 interfaces with the variouscomponents and also with the main controller 250.

In use, the fixture conveyor 240 advances a fixture 302 to the teststation 216. The master connector 850 is then moved from connector 135to connector 135 by the lift and lateral drive mechanisms 851, 853. Ateach connector 135, the test unit is used to take return loss andinsertion loss reading. The test results are stored in memory for use inidentifying which connectors complied with acceptable return loss andinsertion loss parameters.

i. SC Connector Adjust Station

As shown at FIGS. 4, 4E, and 35-37A, the SC connector adjust station 218includes an adjust arrangement 900 having a clamp 902 and a connectorbody receiver 904. The SC connector adjust station 218 also includes alateral drive 911 for moving the adjust arrangement 900 from connectorto connector on a fixture 302, and a lift mechanism 912 for raising andlowering the adjust arrangement 900. See FIG. 36. The SC connectoradjust station 218 further includes a rotational drive 910 for turningthe clamp 902 relative to the connector body receiver 904, and a clampactuator 906 for opening and closing the clamp 902. A controller 913interfaces with the various components of the station and alsointerfaces with the main controller 250.

In use, the fixture conveyor 240 advances a loaded fixture 302 to the SCconnector adjust station 218. Once the fixture is positioned at thestation 218, the lateral drive 911 moves the adjust arrangement 900laterally to a position beneath a first connector 135 held by thefixture 302. The lift mechanism 912 then lifts the adjust arrangement900 to a position where a lower end of the connector 135 (e.g., housing18 shown in FIG. 1) is nested within the connector body receiver 904 toprevent the housing from rotating, and the clamp 902 is aligned with aferrule hub (e.g., hub assembly 20) of the connector 135. The clamp 902then clamps on the ferrule hub of the connector 135. See FIGS. 37 and37A.

Thereafter, the rotational drive 910 rotates the claim 902 andassociated clamped ferrule relative to the housing of the connector 135to adjust the ferrule relative to the key position of the housing.Preferably, the ferrule of the connector is rotated to a position wherethe key aligns with the tuned key position determined at the tuningstation 214. Finally, once the ferrule of the connector 135 is in thedesired rotational position, the clamp 902 releases the ferrule of theconnector 135, and the lift mechanism 912 lowers the adjust arrangement900. The adjust arrangement 900 is then moved by the lateral drive 911from one to the other of the remaining two connectors 135 in fixture 302and the same tuning process is repeated.

In the illustrated embodiment, a laser sensor 915 emits a laser that istrained on external features of the connector 135 such as the hubassembly 20. See FIG. 1. For example, the laser sensor 915 can be usedto verify that the hub assembly 20 of the connector 135 has been rotatedby the adjust arrangement 900.

j. FC Connector Key Press Station

Referring to FIGS. 4, 4F, and 38-39A, the FC connector key press station220 includes a key holder 920 including clamps 932 for clamping eachconnector 135 prior to application of a key element (e.g., key 36 ofFIG. 2, and a pin 933 for holding each key element prior to application.The key holder 920 is moved laterally by a lateral drive 922 and israised up and down by a lift 923. The FC connector key press station 220also includes a product handler 926 for feeding key elements to the keyholder 920. The product handler 926 includes a bin 928 for holding thekey elements and a feed mechanism 930 for feeding the key elements tothe key holder 920. A controller 925 controls operation of the variouscomponents of the station and also interfaces with the main controller250.

In use, the fixture conveyor 240 advances a loaded fixture 302 to thestation 220. Prior to the fixture 302 reaching the station 220, the keyholder 920 is moved so that pin 933 can accept a key from the producthandler 926. When the fixture is positioned at the station 220, clamps932 are closed to capture a portion of the housing of each connector135. Lateral drive 922 moves the pin 933 of the key holder 920 to aposition beneath a first FC connector 135 held by the fixture 302. Thelift 923 then lifts the pin 933 of the key holder 920 to press the keyonto the connector 135. Thereafter, the pin 933 of the key holder 920returns to the product handler 926 to receive another key, and theprocess is repeated until all three connectors 135 held by the fixture302 have been fitted with a key.

k. Dust Cap Installation Station

Referring to FIGS. 4, 4G, and 40-42, the dust cap station 222 includes acap holder 950 that is laterally moved by a lateral drive 951 and israised and lowered by a lift 953. The dust cap station 222 also includesa product handler 955 for conveying dust caps 970 (e.g., dust cap 42 ofFIG. 2) to the dust cap holder 950. The product handler 955 includes abin 957 for storing the dust caps 970 and a conveyor 959 for moving thedust caps from the bin 957 to a location where the dust caps can bepicked up by the dust cap holder 950. A controller 973 controlsoperation of the components of the station and also interfaces with themain controller 250.

In use, the fixture conveyor 240 advances a loaded fixture 302 to thestation 222. Prior to the fixture 302 reaching the station 222, the dustcap holder 950 is moved to accept a dust cap 970 from the producthandler 955. When the fixture 302 is positioned at the station 222,alignment fingers 972 close to align the connector 135 relative to thedust cap holder 950 (see FIG. 41A), and the lateral drive 951 moves thedust cap holder 950 to a position beneath a first connector 135 held bythe fixture 302. The lift 953 then raises the dust cap holder 950 topress the dust cap 970 onto the connector 135. Thereafter, the dust capholder 950 returns to the product handler 955 to receive another dustcap 970, and the process is repeated until all three connectors 135 heldby the fixture 302 have been fitted with a cap 970.

In one embodiment, connectors 135 that fail at any station of system 200(e.g., receive a failing rating at the test station 216) are not fittedwith a dust cap 970. In this manner, the absence of a dust cap 970functions as an indicator for allowing an operator to know whichconnectors 135 failed and which are in need of reprocessing.

1. A method for moving a fiber including a plurality of fiber opticconnectors through a system for processing the plurality of fiber opticconnectors, the method comprising: coupling the plurality of fiber opticconnectors to a fixture; and moving the fixture through the system usinga screw drive.
 2. The method of claim 1, further comprising varying apitch of the screw drive to vary a speed at which the fixture is movedby the screw drive.
 3. The method of claim 1, further comprisingproviding a flat portion defined by the screw drive to allow the fixtureincluding the plurality of fiber optic connectors to be movedindependently from the screw drive.
 4. The method of claim 1, furthercomprising configuring a cycle of the screw drive so that the cycleincludes a moving interval, during which the fixture is moved, and aresting interval, during which the fixture is stationary.
 5. The methodof claim 4, wherein the moving interval of the cycle is approximately ⅔of the cycle.
 6. A method for moving a fiber including a plurality offiber optic connectors through a system for processing the plurality offiber optic connectors, the method comprising: loading the fiber onto acart; loading the plurality of fiber optic connectors into a fixture;moving the cart through the system; and moving the fixture through thesystem.
 7. The method of claim 6, wherein the step of moving the cartfurther comprises moving the cart through the system using a walkingbeam drive.
 8. The method of claim 6, wherein the step of moving thefixture further comprises moving the fixture through the system using ascrew drive.
 9. The method of claim 6, wherein the steps of movingfurther comprise moving the fiber and the plurality of fiber opticconnectors in sequence through the system.
 10. A method for moving afiber including a plurality of fiber optic connectors through a systemfor processing the plurality of fiber optic connectors, the methodcomprising: loading a spool including the fiber onto a cart; loading afixture with the plurality of fiber optic connectors; coupling thefixture to the cart; moving the cart to a start position of the systemfor processing the plurality of fiber optic connectors; detaching thefixture from the cart; using the first drive to move the cart throughthe system; and using the second drive to move the fixture through thesystem.